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Battery Chargers
SERVICE MANUAL / PARTS LIST
AUTOMATIC Advance MODELS 56206980, 56206981, 56372947, 56388109,
56395101, 56388502, 56388120, 56409494, 56411058, 56411643, 56409788,
56205983, 56412272, 56206973, 56372203, 56372190, 56388119
Lester MODELS 56031407, 56632342, 56638431, 56638436, 56638439,
56638440, 56632293, 56031403, 56031405, 56031408
MANUAL MODELS (obsolete) 56206975, 56372945, 56372955
FORM NO. 56041170 / BATTERY CHARGER SERVICE MANUAL / PARTS LIST - 45
Revised 8/00 Form Number 56041170
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Table of Contents
Related Manuals for Nilfisk-Advance 56206980
Summary of Contents for Nilfisk-Advance 56206980
- Page 1 For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net Battery Chargers SERVICE MANUAL / PARTS LIST AUTOMATIC Advance MODELS 56206980, 56206981, 56372947, 56388109, 56395101, 56388502, 56388120, 56409494, 56411058, 56411643, 56409788, 56205983, 56412272, 56206973, 56372203, 56372190, 56388119 Lester MODELS 56031407, 56632342, 56638431, 56638436, 56638439,...
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Page 2: Table Of Contents
On / Off Control Section ..................... 4 Automatic and Manual Timer Battery Charger Troubleshooting ......... 5 Manual Charger PN 56206975 ................. 16 Automatic Chargers PN 56206980 ................17 Manual Charger PN 56372945 ................. 18 Automatic Charger PN 56372947................19 Automatic Charger PN 56388109................20 Manual Charger PN 56372955 ................. -
Page 3: Safety
BATTERY CHARGER SERVICE MANUAL ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ SYMBOLS Nilfisk-Advance uses the symbols below to signal potentially dangerous conditions. Always read this informa- tion carefully and take the necessary steps to protect personnel and property. DANGER! Is used to warn of immediate hazards that will cause severe personal injury or death. -
Page 4: General Information
In addition, an analog multimeter of 10,000 ohms per volt sensitivity or better is required. The Nilfisk-Advance battery charger is comprised of two basic sections; the transformer/rectifier or power section, and the on/off control section. -
Page 5: On/Off Control Section
For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net BATTERY CHARGER SERVICE MANUAL ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ TRANSFORMER / RECTIFIER OR POWER SECTION (continued) The fusing consists of a fuse link in series with each diode and provides overcurrent protection should one or both diodes fail in the shorted mode. -
Page 6: Automatic And Manual Timer Battery Charger Troubleshooting
For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net BATTERY CHARGER SERVICE MANUAL ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ AUTOMATIC TIMER BATTERY CHARGER TROUBLESHOOTING Proper functioning of the Automatic Battery Charger is indicated by the following sequence of events. Three to five seconds after the DC plug is connected to the charger receptacle the control relay “clicks” on, the trans- former hums and the ammeter registers proper charge. - Page 7 For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net BATTERY CHARGER SERVICE MANUAL ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ MANUAL TIMER BATTERY CHARGER TROUBLESHOOTING Proper functioning of the charger is indicated by the following sequence of events. When the timer knob is turned to “ON”, the transformer hums and the ammeter registers proper charge. Proper diagnosing and repair requires identifying the malfunction from the following list, performing the indi- cated tests and repairing or replacing the malfunctioning items.
- Page 8 For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net BATTERY CHARGER SERVICE MANUAL ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ 1-CHECKING FOR COMPLETE ELECTRICAL CONNECTION TO THE BATTERIES Measure and record battery system voltage at the battery posts of the machine. Connect the positive (+) voltmeter lead to the positive (+) battery system post and the negative (-) voltmeter lead to the negative (-) battery system post.
- Page 9 For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net BATTERY CHARGER SERVICE MANUAL ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ 2-TEST FOR PROPER FUNCTIONING OF AUTOMATIC TIMER COMPONENTS With both the AC cord and the charging plug disconnected, remove the cover from the charger. Verify that the charger is wired correctly according to appropriate wiring diagram for the specific part number charger.
- Page 10 For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net BATTERY CHARGER SERVICE MANUAL ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ 3-TEST AC POWER CIRCUIT Measure AC line voltage at the outlet to be sure the correct AC voltage for the specific part number charger is present (115 VAC, or 230 VAC). If the correct AC power is present, disconnect the AC plug and the charging plug.
- Page 11 For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net BATTERY CHARGER SERVICE MANUAL ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ 4-TEST THE CAPACITOR WARNING! It is possible for the capacitor to not be fully discharged. To test for this, adjust your meter to the highest DC voltage scale and touch the test leads to the capacitor terminals and note the reading.
- Page 12 For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net BATTERY CHARGER SERVICE MANUAL ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ 5-TRANSFORMER TESTING Testing the transformer consists of measuring the AC voltage across the transformer secondary leads that connect to the diodes. This voltage is measured first with the capacitor disconnected and compared to the voltage measured with a capacitor connected that has been tested and found good.
- Page 13 For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net BATTERY CHARGER SERVICE MANUAL ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ 5-TRANSFORMER TESTING (continued) • ALTERNATELY The relay contacts can be bypassed to enable transformer testing when the battery system is not present. Make up jumper leads (1 for 115 VAC, 2 for 230 VAC) with 3/16" (4.56 mm) wide flat blade push in connectors on both ends of a piece of 14 gauge flexible wire (Fig.
- Page 14 For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net BATTERY CHARGER SERVICE MANUAL ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ 6-TEST FUSES AND DIODES Disconnect the AC power cord and the charging cord. Set the multimeter to the low resistance scale (R X 1 ) or use a low voltage continuity test light. Excessive heat due to a loose, corroded or distressed connection can cause one or both fuse assembly links to melt and open.
- Page 15 For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net BATTERY CHARGER SERVICE MANUAL ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ 7-CHARGER DC CIRCUIT TEST Disconnect the AC power cord and the DC charger plug. Set multimeter to low resistance scale (R X 1) or use a low voltage continuity tester. Connect one lead of the ohmmeter or continuity tester to one of the DC charging plug contacts, and the other to the remaining DC plug contacts and note the response.
- Page 16 For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net BATTERY CHARGER SERVICE MANUAL ________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________________ 8-AMMETER REMAINS AT MAXIMUM CHARGE FOR MORE THAN 30 MINUTES This condition normally results if the charger is connected to a battery pack which is of lower system voltage than specified in the operaters manual and / or the charger case.
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Page 17: Manual Charger Pn 56206975
For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net BATTERY CHARGER PARTS LIST DIODE RED OR WHT TO DC AMMETER TIMER FUSE PLUG FUSE INLET DIODE PLUG CAPACITOR TRANSFORMER TEST DIAGRAM SECONDARY COIL TIMER SECONDARY TEST POINTS INLET PLUG CAPACITOR TEST POINTS... -
Page 18: Automatic Chargers Pn 56206980
JUMPER SECONDARY TEST POINTS INLET PLUG CAPACITOR TEST POINTS CAPACITOR COIL PARTS LIST FOR APA BATTERY CHARGER PART NUMBER 56206980 24 VOLT 10 AMP AUTOMATIC 120 VAC 60 HZ Item Part No. Description 56206904 Heatsink Assembly, With Diodes 56206905 Ammeter... -
Page 19: Manual Charger Pn 56372945
For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net BATTERY CHARGER PARTS LIST DIODE RED OR WHT FUSE TO DC AMMETER TIMER ASSY PLUG INLET DIODE PLUG CAPACITOR TRANSFORMER TEST DIAGRAM SECONDARY COIL TIMER SECONDARY TEST POINTS INLET PLUG CAPACITOR TEST POINTS... -
Page 20: Automatic Charger Pn 56372947
For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net BATTERY CHARGER PARTS LIST ELECT. TIMER TRANSFORMER DIODE RELAY TO DC PLUG FUSE AMMETER ASSY INLET PLUG DIODE CAPACITOR TRANSFORMER TEST DIAGRAM RELAY PRIMARY COIL SECONDARY COIL JUMPER SECONDARY TEST POINTS INLET PLUG... -
Page 21: Automatic Charger Pn 56388109
For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net BATTERY CHARGER PARTS LIST ELECT. TIMER RELAY DIODES TRANSFORMER TO DC PLUG FUSE AMMETER ASSY INLET PLUG DIODES CAPACITOR TRANSFORMER TEST DIAGRAM RELAY PRIMARY COIL SECONDARY COIL JUMPER SECONDARY TEST POINTS INLET PLUG... -
Page 22: Manual Charger Pn 56372955
For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net BATTERY CHARGER PARTS LIST DIODE RED OR WHT FUSE TO DC AMMETER TIMER ASSY PLUG INLET DIODE PLUG CAPACITOR TRANSFORMER TEST DIAGRAM SECONDARY COIL TIMER SECONDARY TEST POINTS INLET PLUG CAPACITOR TEST POINTS... -
Page 23: Automatic Charger Pn 56395101 (Replaces Pn's 56372947 & 56395347)
For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net BATTERY CHARGER PARTS LIST ELECT. TIMER TRANSFORMER DIODE RELAY TO DC PLUG FUSE AMMETER ASSY INLET PLUG DIODE CAPACITOR TRANSFORMER TEST DIAGRAM RELAY PRIMARY COIL SECONDARY COIL JUMPER SECONDARY TEST POINTS INLET PLUG... -
Page 24: Automatic Charger Pn 56388502
For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net BATTERY CHARGER PARTS LIST ELECT. TIMER TRANSFORMER DIODE RELAY TO DC PLUG FUSE AMMETER ASSY INLET PLUG DIODE CAPACITOR TRANSFORMER TEST DIAGRAM RELAY PRIMARY COIL SECONDARY COIL JUMPER SECONDARY TEST POINTS INLET PLUG... -
Page 25: Automatic Charger Pn 56388120
For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net BATTERY CHARGER PARTS LIST ELECT. TIMER RELAY DIODES TRANSFORMER TO DC PLUG FUSE AMMETER ASSY INLET PLUG DIODES CAPACITOR TRANSFORMER TEST DIAGRAM RELAY PRIMARY COIL SECONDARY COIL JUMPER SECONDARY TEST POINTS INLET PLUG... -
Page 26: Automatic Charger Pn 56409494
For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net BATTERY CHARGER PARTS LIST 200-220/221-250 VAC INPUT SHUNT TRANSFORMER FUSE BLACK BLACK BROWN TO DC AMMETER FUSE PLUG GREEN BLACK 200-221 BLACK BLACK SETTING BLACK WHITE ORANGE 221-250 SETTING WHITE FUSE BLACK... -
Page 27: Automatic Charger Pn 56411058
For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net BATTERY CHARGER PARTS LIST ELECTRONIC TIMER BLACK GREEN DIODE TRANSFORMER RED OR WHITE TO DC PLUG FUSES BLACK BLACK BLACK AMMETER DIODE BLACK LOW BATTERY VOLTAGE START GREEN SWITCH WHITE 115 VAC INPUT... -
Page 28: Automatic Charger Pn 56411643
For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net BATTERY CHARGER PARTS LIST ELECTRONIC TIMER BLACK GREEN RELAY DIODE TRANSFORMER ORANGE WHITE CIRCUIT TO DC BREAKERS PLUG BROWN BLACK BLACK BLACK WHITE BLACK AMMETER DIODE LOW BATTERY VOLTAGE START BLACK SWITCH GREEN... -
Page 29: Automatic Charger Pn 56409788
For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net BATTERY CHARGER PARTS LIST AMMETER FUSE BLACK BLACK TRANSFORMER BLACK 11 12 13 14 BLACK BROWN ASS'Y BLACK BROWN BLACK (-) 200- 220- FUSE SHUNT TO DC BLACK (+) PLUG FUSEHOLDER OUTPUT... -
Page 30: Automatic Charger Pn 56205983 (Replaces Pn 56206981)
For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net BATTERY CHARGER PARTS LIST POWER THERMAL SWITCH PROTECTOR TRANSFORMER BLACK FUSE CONTROL WHITE GREEN BOARD WHITE OUTPUT INPUT BLACK PARTS LIST FOR APA BATTERY CHARGER PART NUMBER 56205983 (replaces part number 56206981) 24 VOLT 12 AMP AUTOMATIC 120 VAC 60 HZ Part No. -
Page 31: Automatic Charger Pn 56412272
For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net BATTERY CHARGER PARTS LIST CAPACITOR HEATSINK ASSEMBLIES WITH DIODES ELECTRONIC TIMER KIT BLACK RELAY DC OUTPUT POLARITY POSITIVE: +, WHITE OR RED. NEGATIVE: -, BLACK DC CORDSET BLACK SECONDARY WHITE OR RED (+) PRIMARY BLACK (-) -
Page 32: Automatic Charger Pn 56206973
For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net BATTERY CHARGER PARTS LIST CAPACITOR HEATSINK ASS'Y W/DIODES ELECTRONIC TIMER ASS‘Y BLACK GREEN OUTPUT POLARITY: NEGATIVE: -, OR BLACK POSITIVE: +, RED OR WHITE SECONDARY RELAY BLACK (-) OUTPUT BATTERIES BUSHING PRIMARY... -
Page 33: Automatic Charger Pn 56372203
For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net BATTERY CHARGER PARTS LIST CAPACITOR HEATSINK ASS'Y W/DIODES ELECTRONIC TIMER ASS’Y BLACK GREEN OUTPUT POLARITY: NEGATIVE: -, OR BLACK SECONDARY POSITIVE: +, RED OR WHITE RELAY BLACK (-) BLACK OUTPUT BATTERIES BUSHING... -
Page 34: Automatic Charger Pn 56372190
For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net BATTERY CHARGER PARTS LIST CAPACITOR HEATSINK ASS'Y W/DIODES ELECTRONIC TIMER ASS’Y BLACK GREEN OUTPUT POLARITY: NEGATIVE: -, OR BLACK SECONDARY POSITIVE: +, RED OR WHITE RELAY BLACK (-) BLACK OUTPUT BATTERIES BUSHING... -
Page 35: Automatic Charger Pn 56388119
For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net BATTERY CHARGER PARTS LIST CAPACITOR HEATSINK ASS'Y W/DIODES ELECTRONIC TIMER ASS’Y BLACK GREEN OUTPUT POLARITY: NEGATIVE: -, OR BLACK SECONDARY POSITIVE: +, RED OR WHITE RELAY BLACK (-) BLACK OUTPUT BATTERIES BUSHING... -
Page 36: Automatic Charger Pn 56031407
For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net CAPACITOR HEATSINK ASSEMBLIES WITH DIODES ELECTRONIC TIMER KIT BLACK RELAY DC OUTPUT POLARITY POSITIVE: +, WHITE OR RED. NEGATIVE: -, BLACK DC CORDSET BLACK SECONDARY WHITE OR RED (+) PRIMARY BLACK (-) GROUNDED... -
Page 37: Automatic Charger Pn 56632342
For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net HEATSINK ASSEMBLY CAPACITOR WITH DIODES ELECTRONIC TIMER KIT RELAY BLACK GREEN* DC CORDSET SECONDARY BLACK WHITE OR RED (+) PRIMARY BLACK BLACK (-) BATTERIES GROUNDED AC INPUT BLACK GREEN FUSE *GREEN WIRE NOT USED AMMETER... -
Page 38: Automatic Charger Pn 56638431
For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net DIODE HEATSINK ASSEMBLY CAPACITOR ELECTRONIC TIMER ASSEMBLY BLACK GREEN DC CORDSET OUTPUT BROWN ORANGE BUSHING SECONDARY BATTERIES BLACK BLACK PRIMARY GROUNDED AC INPUT BLACK GREEN WHITE INPUT FUSE AMMETER BUSHING CORDSET ASSEMBLY... -
Page 39: Automatic Charger Pn 56638436
For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net POWER THERMAL SWITCH PROTECTOR TRANSFORMER BLACK FUSE CONTROL GREEN WHITE BOARD WHITE OUTPUT INPUT BLACK PARTS LIST FOR LESTER BATTERY CHARGER PART NUMBER 56638436 24 VOLT, 12 to 3 AMP AUTOMATIC 120 VAC 60 HZ Part No. -
Page 40: Automatic Charger Pn 56638439
For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net CAPACITOR HEATSINK ASSEMBLIES WITH DIODES ELECTRONIC TIMER KIT BLACK RELAY DC OUTPUT POLARITY POSITIVE: +, WHITE OR RED. NEGATIVE: -, BLACK DC CORDSET BLACK SECONDARY WHITE OR RED (+) PRIMARY BLACK (-) GROUNDED... -
Page 41: Automatic Charger Pn 56638440
For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net POWER AC VOLTAGE * SHUNT SWITCH SELECTOR FUSE OUTPUT SWITCH BLACK BLACK WHITE 40 AMP AMMETER BLACK CIRCUIT BREAKER 10 BLACK BLACK BLACK BLACK BLACK GREEN BROWN BROWN WHITE GRAY 100-125 200-225... -
Page 42: Automatic Charger Pn 56632293
For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net HEATSINK ASSEMBLY CAPACITOR WITH DIODES ELECTRONIC TIMER KIT RELAY BLACK GREEN* DC CORDSET SECONDARY BLACK WHITE OR RED (+) PRIMARY BLACK BLACK (-) BATTERIES GROUNDED AC INPUT BLACK GREEN *GREEN WIRE NOT USED FUSE AMMETER... -
Page 43: Automatic Charger Pn 56031403
For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net DIODE HEATSINK ASSEMBLY CAPACITOR ELECTRONIC TIMER ASSEMBLY BLACK GREEN DC CORDSET OUTPUT BROWN ORANGE BUSHING SECONDARY BATTERIES BLACK BLACK PRIMARY GROUNDED AC INPUT BLACK GREEN WHITE INPUT FUSE AMMETER BUSHING CORDSET ASSEMBLY... -
Page 44: Automatic Charger Pn 56031405
For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net POWER AC VOLTAGE * SHUNT SWITCH SELECTOR OUTPUT FUSE SWITCH BLACK BLACK WHITE 40 AMP AMMETER BLACK CIRCUIT BREAKER 10 BLACK BLACK BLACK BLACK BLACK GREEN BROWN BROWN WHITE GRAY 100-125 200-225... -
Page 45: Automatic Charger Pn 56031408
For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net CAPACITOR HEATSINK ASSEMBLIES WITH DIODES ELECTRONIC TIMER KIT BLACK RELAY DC OUTPUT POLARITY POSITIVE: +, WHITE OR RED. NEGATIVE: -, BLACK DC CORDSET BLACK SECONDARY WHITE OR RED (+) PRIMARY BLACK (-) GROUNDED... - Page 46 For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net Nilfisk-Advance, Inc. 14600 21st Avenue North Plymouth, MN, 55447-3408 www.nilfisk-advance.com Phone: 800-989-2235 Fax: 800-989-6566 ©2000 Nilfisk-Advance, Inc., Plymouth, MN 55447-3408 Printed in the U.S.A. For new, refurbished and used cleaning equipment and supplies visit www.southeasternequipment.net...
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